Ford Focus Service Manual: Windshield Glass

	Deluxe Windshield Removal Tool 164-R2450 or equivalent
	The Pumper 164-R2459 or equivalent

Removal

1. Remove the cowl panel grille. For additional information, refer to Section  501-02.

1. Remove the A-pillar trim panels. For additional information, refer to Section  501-05.

1. Remove the interior mirror. For additional information, refer to Section  501-09.

1. Remove the sun visors and retaining clips. For additional information, refer to Section  501-05.

1. Partially lower the front portion of the headliner near the windshield header and block with suitable material.

1. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield pinch weld area.
   • Use a clean shop towel or oil-free compressed air.

1. NOTE:

   Refer to manufacturer's instructions before using the Deluxe Windshield Removal Tool.

   Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool when cutting the urethane adhesive.

1. WARNING: Always
   wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.

   WARNING: Wear
   protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.

   NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer, or otherwise damage the pinch weld during glass removal.

   NOTE:

   Insert the blade into the Deluxe Windshield Removal Tool so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinch weld and allow a dry fit of the replacement windshield glass.

   NOTE:

   Support the windshield glass as necessary to prevent the glass from dropping while cutting the urethane adhesive.

   Insert the Deluxe Windshield Removal Tool at the upper center of the windshield glass and work toward the bottom corners.

1. Using The Pumper, distance the windshield glass from the body.

1. Using the Deluxe Windshield Removal Tool, cut the remaining urethane adhesive and remove the windshield glass and place on a stable work surface.

Installation

1. Dry-fit the new windshield glass on the existing urethane adhesive bead on the pinch weld.
   • Position the windshield glass on the pinch weld.
   • Center the windshield glass in the opening.
   • Adjust the windshield glass stop blocks (if equipped) as needed for best fit.
   • Make alignment marks with tape or non-staining grease pencil (preferably at the windshield glass stop blocks if equipped) on the windshield glass and the body.

1. After the dry-fit alignment, remove the glass from the windshield opening and place on a stable work surface with the interior side of the glass facing up.

1. WARNING: Repair
   any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

   NOTE:

   Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and urethane adhesive.

   Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm (0.04 in to 0.08 in) base of original equipment urethane adhesive on the pinch weld.

1. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the existing urethane adhesive. Remove any foreign material or water that may have entered during windshield removal.

1. If reinstalling the same windshield glass, remove the remaining urethane adhesive from the glass leaving a thin layer to bond with the new urethane adhesive bead.

1. Clean the inside of the new windshield glass with glass cleaner.

1. NOTE:

   Be sure to use the same brand and cure-rate products for the urethane adhesive and glass primer. Do not mix different brands of urethane adhesive and glass primer. Refer to the Material Chart in this procedure.

   If installing a new windshield glass, apply glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry.

1. Cut the urethane adhesive applicator tip to specification.

1. NOTE:

   The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.

   NOTE:

   Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane adhesive with less effort and continuous bead.

   Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld, starting and ending at the bottom of the windshield near the center, making sure there are no gaps in the bead.

1. WARNING: Do
   not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).

   NOTICE: Before positioning the windshield glass, open vehicle windows to prevent the air pressure of closing doors from affecting the urethane adhesive bond.

   Using the alignment marks made previously, position the windshield glass on the pinch weld.

1. NOTE:

   The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.

   After the urethane adhesive cures, check the windshield glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.

1. Install the headliner, sun visors and retaining clips. For additional information, refer to Section  501-05.

1. Install the interior mirror. For additional information, refer to Section  501-09.

1. Install the A-pillar trim panels. For additional information, refer to Section  501-05.

1. Install the cowl panel grille. For additional information, refer to Section  501-02.